There’s no question that concrete is one of the longest-lasting and most economical building materials. The fact that concrete actually gets stronger over time makes it a winner over other construction materials, like wood, for example. Believe it or not, there are actually 23 different types of concrete used in today’s modern construction industry. These types can be used in different applications to achieve a variety of results. But today, it’s the process we want to discuss: Precast concrete versus cast-in-place (CIP) concrete. What’s better? To answer that question, let’s take a look at each process, the advantages of each and, of course, your desired outcome.

What is Precast Concrete? 

Precast concrete products are cast at a factory. The concrete, a mixture of cement, water, aggregates and admixtures, is placed into a form and cured before being stripped. These products are then delivered to the construction site for erection into place. Precast products can include concrete bricks or stones, structural components and wall panels, to name just a few.

What Are the Advantages of Precast Concrete? 

The benefits of precast concrete are most notably speed, durability, efficiency and quality. However, perhaps the most important characteristic is the material’s flexibility. Precast concrete can be used in a variety of applications making it appealing to architects, developers, general contractors and designers alike.

Working with precast concrete offers the following advantages:

• Speed: Not only can products be cast while foundation work is in progress, but precast concrete components can be cast and erected year-round regardless of weather conditions.
• Durability: Concrete is by nature a highly-durable material that is resistant to wear, weather and damage.
• Energy Efficiency: Concrete’s high thermal mass conserves energy, and the use of insulated panels only enhance that attribute.
• Environmentally Friendly: Precast concrete is clean and waste-free, and the addition of by-products reduces requirement for cement in the mix, as evidenced by the ability to obtain LEED certification.
• High Quality: Since products are cast in a factory, quality control is very high and allows for a single source provider.
• Aesthetic Flexibility: Precast can mimic granite, limestone, brick and other masonry products and can be finished in variety of textures and colors.
• Design Flexibility: Precast concrete members can handle higher loading and longer span capabilities providing more flexibility with office and parking structures.

What is Cast-in-Place (CIP) Concrete? 

CIP (or site cast) concrete is prepared at local plants for construction site delivery via trucks with revolving drums. Once the concrete arrives, the walls and slabs are cast at the site in the formwork. CIP concrete requires a strength test and additional time for curing on-site. Sometimes it can be hard to control the mix when weather conditions are a factor.

What Are the Advantages of CIP Concrete? 

Strength, reduced transportation and insulation are the primary benefits of site cast concrete. While concrete is an inherently strong material, CIP concrete is preferred for laying foundations and basement walls. It is also relatively resistant to structural damage due to earthquakes, floods or other natural disasters. Since site cast concrete is cast at the construction site, there is no need for transportation of finished products. On the flip side, this process requires more labor onsite to ensure proper and timely pouring, molding and curing. Finally, since this type of concrete is poured on-site, there is a fewer occurrence of natural cracks or gaps between walls leading to insulation properties that extend to insects, mold and mildew.

Designing with Precast Concrete 

Developers, architects, designers and contractors come together on a building project to achieve a desired outcome. Usually each party has several challenges to overcome and the desired outcome is a cohesive look and feel that capitalizes on function and efficiency. Here’s some common issues that may arise during the planning process and how precast concrete can offer a solution. Check out the Precast/Prestressed Concrete Institute (PCI) design resources for more information.

How can I ensure sufficient structural support for computer and storage systems in an office building or distribution center? High-strength flooring provides support for heavy loads now and in the future. Take a look at this data center.

Can using precast concrete increase energy efficiency? Yes, the material’s inherent thermal mass helps regulate temperatures but insulated precast concrete sandwich panels provide added energy efficiency due to insulation in the core.

How do I minimize congestion and safety concerns on-site and in the general vicinity during construction? Since precast concrete products can be delivered to the site as needed for that day’s erection, staging areas can be arranged nearby ensuring less traffic on-site and less congestion in the vicinity.

Can I create tall, open interiors with precast to allow for flexible merchandising space? Yes, architectural precast concrete panels can be designed to provide high ceilings. Check out this retail project.

What about delivery docking space? How can I accommodate trucks? Precast concrete panels’ capability to be cast in 12-feet widths or wider allows docking doors to be built into a single panel, providing inherent stability and fast erection. Take a look at this cargo center.

Can precast concrete materials help me create a design that complements surrounding buildings while also meeting brand requirements? Architectural precast concrete panels use colors, textures, reveals, finishes, form liners, or thin-brick insets to match any needed design style. These looks can be used for warehouse type retailers, additions to malls, stand-alone stores and more.

How can I design open interior spaces to maximize parking layout and provide a secure environment? Double tees can span long distances to eliminate columns and provide unobstructed view through the levels. Moment frames, k frames, lite walls and other unique structural supports can open interiors and smooth traffic flow. Check out this open parking deck.

How do I create high fire resistance? Precast concrete’s non-combustible composition minimizes the spread of fire, while compartmentalization design techniques provide time for detection, evacuation and suppression.

How can I create long-span areas like gymnasiums and pools? The use of precast hollow-core slabs and double tees can span long distances to minimize or eliminate columns where needed. Take a look at this recreation center.

What about noise? Can using precast concrete materials control acoustics? Yes, precast concrete wall panels, especially insulated panels, minimize noise between units.

I’m working with strict zoning requirements. How can I minimize floor-to-floor heights? Hollow-core slabs can serve as a combined ceiling/flooring unit, reducing the building’s height.

There are many factors to consider when choosing materials – and partners – for your project. Precast concrete continues to evolve as designers expand the applications of the material. ATMI Precast is a full-service precast construction company. We service a broad spectrum of project types, from mid-rise office to residential and parking and look forward to working with partners who will push the boundaries and create innovative projects. Long recognized as a leader in the field, ATMI Precast has earned customer recognition for our reliable performance, quality and service throughout the precast concrete construction process.

In 1983 Automatic Teller Modules, Inc. was formed by two Aurora families. One family, a second-generation family architectural firm specializing in financial institutions, and the other a third-generation family in concrete products and construction. The company was initially formed to fabricate and install modular buildings housing ATM machines – hence the name “Automatic Teller Modules, Inc.” The modular ATM buildings were precast concrete.

By 1985 the original firm had progressed to modular branch banks using precast concrete construction and full design build services for suburban branch banks also using precast concrete. The company began doing business as ATMI Design + Build. In 1987 ATMI Design + Build secured a multi-year contract with a large national financial institution to design and build a prototype branch bank and multiple replications each year for many years to come. The architectural piece was with the existing family firm, ATMI Design + Build brought the construction piece and the structure was precast, which closed the branch in rapidly for other trades to start.

The precast was a specialty architectural product and was being produced by a small, unrelated fabricator in Aurora, Illinois.  At the beginning of 1989 the small specialty precast fabricator was showing signs of distress in the midst of trying to produce multiple branch banks. ATMI Design + Build found itself in a situation of a key supplier for all of these banks in jeopardy.

By the summer of 1989, the principles of ATMI Design + Build and another member of the concrete products family (who had recently sold the family concrete products business) formed a new entity to produce the precast structures for the branch banks under a multi-year commitment. Since Automated Teller Modules, Inc. has been shortened to ATMI, the new entity formed to fabricate precast was named ATMI Precast, Inc. – which remains today.

In 1991, the national financial institution was itself distressed and the multi-year branch bank program was cancelled due to all capital expenditures being stopped on a national basis. The architectural firm had a contract for a new casino and parking deck and it was to be designed with precast. This order provided a life line in the absence of the branch bank orders for ATMI Precast.

By 1993, ATMI Precast re-focused on the industrial building market and built core relationships with the developers and builders in this market. Two years later, the industrial building market was driven by large public REIT’s. In addition, technology was allowing 30-foot clear height buildings and wider panels to accommodate dock doors. The market expanded beyond capacity for all of the key players including production capacity at ATMI Precast. As a result, ATMI Precast went from less than 500,000 square feet of walls fabricated in 1995 and 40 employees to over eight million square feet of walls, two million square feet of hollow core plank, over 500 employees, and the addition of two other fabrication facilities by 2006.

Today the ATMI Companies, consisting of ATMI Precast and ATMI Indy, LLC., fabricate approximately 19,000 pieces, nine million square feet of product, and 16,000 outbound over width, overweight, permitted truckloads to approximately 150 buildings per year. The ATMI Companies, service the industrial building market, the parking deck market, the urban multi-story retail market, and multi-story residential markets.

As one of the leading independent precast concrete manufacturers in the Midwest, ATMI Precast employs approximately 200 plant employees. Back in 2013 we were facing some workers’ compensation obstacles we wanted to overcome. The goal was to create a culture of safety to minimize risk in the workplace that would ultimately improve internal claims management practices. To do this, we turned to our business partner, Assurance, for guidance and together, we formulated a strategy that would meet all of our objectives.

“We recognized we needed to implement new protocols and initiatives in order to manage our rising workers’ compensation challenges,” said Mike Pelz, Vice President Operations, ATMI Operations.

To start, ATMI created a Safety Director position to review and develop an annual employee safety training schedule. We also aligned with a new insurance carrier that would better meet our needs, including ongoing claim reviews and ad hoc follow-ups.

ATMI Precast’s Keys to Success

The key to our success was total buy-in from the top down to create a culture of safety. Taking immediate action was also important. We implemented a safety training process with new hire orientation videos that uses our own employees.

ATMI Precast implemented additional safety practices including:

» Daily inspection forms and equipment checks for all foremen

» Monthly facility safety inspections with a focus on OSHA compliance

» New accident investigation guidelines and amended job descriptions

» New surveillance system to prevent fraudulent claims and ensure employee safety

» Significant improvements to their facility to increase efficiency

To improve employee involvement in the new safety program, the Safety, Excellence, Accountability, Leadership (S.E.A.L.) Team was created. Members of the S.E.A.L. Team must submit safety suggestions, demonstrate safe behavior, report unsafe acts/conditions, inspect equipment and tools, follow best housekeeping practices and demonstrate leadership. Additionally, to promote an ongoing safety culture, if certain employee safety parameters are achieved, a company-wide celebration lunch is provided.

ATMI Precast Results

ATMI Precast exceeded industry standards through our focus on safety, claims and risk management. Between 2013-2018, we successfully improved our loss ratio by 93%. From 2017 to 2018, our Experience Modification Rating (a number that influences a company’s workers’ compensation costs) was improved by 37 Points. ATMI Precast also decreased average claim costs by 79% in the last year and enjoyed a $300,000 premium reduction in 2018.

As a result, ATMI Precast was awarded the 2019 Minimizing Risk, Maximizing Health (MRMH) Award by Assurance.

“This award represents our dedicated efforts to our employee’s safety, as well as accomplishing lower claim costs,” Pelz said.

Choosing precast concrete for your construction project can directly impact your bottom line throughout all phases of construction and for everyone involved. One of the many benefits of precast concrete is the inherent versatility and reliability of the product itself, which makes it a top choice for a variety of markets, including: industrial, institutional, corporate, parking decks, residential, and retail.

In order to pull off a large-scale development, the owner, architect, general contractor, and engineer must all work together to stay on time and on budget while achieving a functional, aesthetically-pleasing building that meets several guidelines and standards. Learn how using precast concrete can save you money before construction begins, during the construction process, and well after the project is finished.

Pre-Construction Savings

Long before any work is done on-site, choosing precast concrete for your construction project can boost your bottom line. Pre-construction planning takes into account overhead costs, the design, and the all-important timeline. Working with precast concrete can help you save money in all of these areas.

>>Cut Overhead Costs

Precast concrete uses molds and forms to create different products necessary to achieve a total precast building system. For example, the ATMI Precast plant houses 20 production tables for manufacturing of precast beams, double TT’s, insulated or solid precast wall panels, columns, slabs, and more. These molds and forms can be recycled and re-used many times – therefore cutting overhead costs and saving you money. On the other hand, on-site concrete construction requires forms to be built from scratch for each project.

>>Stay Within Design Budgets

Precast concrete provides a variety of color, textures, and finishes, meaning it can serve as an affordable alternative to more expensive stone, masonry or tile. In fact, ATMI Precast can provide creative solutions such as inset brick and the use of liners to simulate natural stones.

Additionally, the molds can include design elements that can enhance appearance and presentation in your construction project. Keeping the design budget in check while still achieving your desired look and feel is key.

>>Reduce Weather Delays

Using precast concrete for your project means that you can get started right away. Not only can multiple project components get done at once, but the indoor, controlled environment means that your precast construction will stay on schedule, regardless of what Mother Nature has in store. This means, your project will get the green light no matter the time of year – because after all, time is money.

Construction Savings

When it’s time to get on-site and start building, you can count on precast concrete to cut your costs yet again. Using precast means that you can reduce your transportation and labor costs, minimize risk to your on-site workers, and forge ahead with a quality product that won’t let you down.

>>Slash Transportation Costs

Due to the fact that precast concrete products are constructed at one location and then transported on-site when ready, your general contractor doesn’t have to worry about multiple trade transports, making the operation cleaner and more efficient. Less workers, less equipment and less vehicles equates to less headaches and less expenses.

>>Minimize On-Site Accidents & Exposure

We know that the safety of your construction site is always a priority. One of the benefits of working with precast concrete and its off-site casting, which eliminates the need for other trades to work erecting structural frame. Furthermore, when working with precast, the dust exposure is limited almost exclusively to within the precast plant. A safe working environment is not only best practice, but it reduces any Workers’ Compensation costs as well.

>>Depend on Quality

Working with a reputable precast manufacturer means you have partnered with a company that commits to meeting high standards and delivers a quality product that you can rely on during the construction process. For example, ATMI Precast is certified through the Precast Concrete Institute (PCI). Working with ATMI ensures a high-quality precast product.

Post-Construction Savings

When your project is complete it’s out of your hands. But, in order to attract tenants, you have to be able to sell the features of your building. Of course, these plans may have been made in the pre-construction phase if you are building a facility for a specific occupant or use. Either way, these post-construction savings are what people are looking for.

               >>Save on Maintenance

Concrete is a hard and highly-durable material that is resistant to wear, weather, and damage. Sustainability is evidenced by precast concrete’s ability to facilitate LEED Certification. The investment value of a building increases if the structure lasts longer than expected. Furthermore, exterior precast concrete can be left untreated without damage from the elements. And, if painted, repainting is necessary only every five to ten years.

               >>Reduce Energy Costs

Precast concrete is highly energy efficient as concrete intrinsically retains heated or cooled air. This saves money on energy bills and reduces the overall energy load of the building. This is an important asset for designers who need to cut heating and air conditioning costs associated with HVAC systems – and it is an important selling point for precast concrete products.

               >>Be a Friend to the Environment

Precast concrete is completely recyclable, making it an environmentally-friendly choice. Concrete consists of water, sand, gravel and cement. To make the cement, gypsum is added to limestone, clay, sand and iron ore and the mixture is finely ground. This means that precast as a construction material is clean and waste-free, and the addition of by-products reduces requirement for cement in the mix.

Precast concrete provides unique benefits that can be found with no other material because it is naturally based and offers exceptional building aesthetics. Together with structural ability, speed, and economy, precast building construction is an unparalleled choice to get the most out of your project.

The Precast/Prestressed Concrete Institute (PCI) represents the summation of the precast/prestress concrete industry’s innovation, design, inspection, and process improvements gained since 1954. As an ISO 9001;2015 recognized and IAS (International Accreditation Service) Accredited Quality Program, PCI’s plant certification serves as the industry’s benchmark in quality system standards worldwide. ATMI Precast is proud to be PCI-certified.

What Does PCI Certification Mean for ATMI Precast?

To earn and maintain PCI certification, plants must demonstrate their commitment to quality through:

• The development of a comprehensive Quality System Manual
• The utilization of an established Multi-step Inspection Process for all products
• The successful completion and response to Unannounced Bi-annual Quality Audits through a third-party auditor
• The completion and documentation of Annual Internal Audits
• The completion and documentation of Continuous Root Cause Analysis and Process Improvements
• Plant Personnel Training Certification through PCI
• Regularly Maintained Calibration Intervals for all necessary Quality and Production Department equipment
• The completion and documentation of Approved Vendors for all materials

ATMI Precast is proud to be a PCI Certified plant for nearly 20 years!

What Does PCI Certification Include at ATMI Precast?

Our current product certifications through PCI include:

• Category A1 Architectural Products
  • Includes exterior cladding, loadbearing, and non-load-bearing wall panels, spandrels, beams, columns, and et al.
  • These products typically have more stringent requirements for dimensional tolerances, finish variations, and color consistency.
• Category C3A Commercial (Structural) Products
  • Precast concrete structural members that are Prestressed with straight, pretensioning, or post-tensioning. Includes stemmed members for roofs, floors, and walls, as well as beams, columns, spandrels, joists, and similar products.
  • These products may have a special architectural finish and/or suitable for painting if specified.

We strive to not only exceed industry standards, but rather our customer’s standards. The proven consistent quality of ATMI Precast products, demonstrates our commitment to quality on all phases of your project.

Adequate and efficient space for parking is an essential component of a successful building design. For most of our clients, standard surface parking is not an option. The solution is usually a multi-level parking structure that is both functional and complements your building design. There are a few options when it comes to the type of concrete you can use for parking structures: precast concrete or cast-in-place (CIP) concrete.

The Precast Concrete Institute (PCI) publishes a variety of resources that provide guidance on designing, fabricating and constructing precast concrete structures. We’ve drawn from PCI’s Parking Structure System Comparison publication to highlight how precast concrete and cast-in-place concrete differ when building parking decks. Specifically, we’ll discuss how these materials compare when it comes to the construction schedule, cost, site considerations, constructability and quality, interior and exterior aesthetics, maintenance, and sustainability.

Your Schedule, The Cost & Site Considerations

For the sake of comparison, let’s define a typical parking structure as a 4-story garage with 1,000 stalls. When working with precast concrete, the average construction schedule is 6 to 8 months. Cast-in-place concrete requires a bit more time, averaging 10 to 12 months. The timeline is a big deal. Less construction time potentially means less financing costs and a shorter time to revenue. Furthermore, a reduced schedule greatly impacts site considerations. For example, using cast-in-place concrete has the greatest site impact as more labor (and more space for lay-down) is necessary. A precast concrete construction site means less workers, less space and minimal to zero construction waste. All of these factors impact your bottom line.

Material Constructibility & Quality

The biggest variance when it comes to material constructibility and quality is how the products are created. Precast concrete products are produced at a PCI certified facility – like ATMI Precast – under stringent audited guidelines and procedures. Cast-in-place concrete products are cast at the job site. Naturally that means varying conditions could affect the quality of the products dependent upon the weather conditions during placement and curing as well as availability of quality labor.

Additionally, precast concrete is stronger. Typical precast concrete holds up to more than 6,000 psi whereas CIP holds anywhere from 4,000 to 5,000 psi. Bonded prestressed strands (associated with precast concrete) are more protected from corrosion. When structural damage does occur, due to corrosion, it is localized to an individual precast concrete member. On the other hand, unbonded post-tensioning (associated with CIP concrete) creates the potential for future corrosion when water gets into the sheathing – eventually making large areas of the garage structurally deficient.

Interior & Exterior Aesthetics

While the inside look of a parking garage may not seem important, an open, well-lit space is conducive to safe driving – and less accidents. Interior features of a precast concrete parking structure include fewer columns, which leads to a more expansive view and lots of natural light. The floor is more likely to stay uniform throughout with very little shrinkage and temperature cracking. Of course, on the flip side, CIP concrete requires more columns and due to fewer floor joints, shrinkage and temperature cracks are to be expected.

A parking garage is expected to look like it’s part of the building it serves. Therefore, exterior aesthetics are a big part of the overall design plan. This is another area where precast concrete takes the lead. Precast concrete architectural finishes can be integrated into the precast concrete elements from the get-go at a minimal cost. Essentially, this means the exterior design is baked into the product and ready to go once constructed. CIP concrete parking structures typically require a secondary system like architectural precast concrete, EIFS coating, metal panel screening systems, or painted spandrels to achieve the desired aesthetic.

Maintenance & Sustainability

Surface upkeep for both materials is relatively the same. CIP concrete is most likely to get corrosion of load-carrying capacity reinforcing steel and post-tensioning strand due to potential poor concrete cover – leading to severe spalling over time. While it’s very rare for precast concrete to deteriorate, the CIP concrete topping slab could have problems if poured with low-quality concrete, if the joints are not tooled properly, or if it is not protected from wind or temperature during the curing phase.

As mentioned above, working with precast concrete delivers the smallest possible construction footprint – which leads to overall better sustainability. Additionally, precast concrete products can be re-used. Since the components are individual, they could be deconstructed and used elsewhere. This isn’t the case with a CIP concrete parking garage.

Precast concrete elements may include reinforcing as well as supplementary cementitious materials (SCMs) which replace some of the cement content of the concrete – helping to lower the carbon footprint of the structure. SCMs are easier to use in precast concrete since the primary curing happens at the manufacturer’s plant before structural loads are placed on the components.

Of course, the type of concrete you use all depends on your desired outcome in your location. But we can make a case for precast concrete parking garages all day long! Take a look at some of our parking deck projects and let us know what you think.

To read all of the technical details, download PCI’s Parking Structure System Comparison.

Are you familiar with the phrase: Hindsight is 2020? As we’re nearing the end of the year, this phrase has never been more relevant. It’s been a hard year for a lot of people, for a lot of reasons. But instead of looking at what we’ve all had to overcome this year, ATMI Precast has decided to look at our triumphs.

We kicked off 2020 with a full industrial backlog and hit the ground running in January. Of course, by mid-March the spread of COVID-19 had impacted life as we know it. For ATMI Precast, that translated to an immediate loss of 25% of our backlog.

How ATMI Precast Handled COVID this Year

Right away we reduced our plant capacity with about 200 employees. Our management worked diligently with plant personnel to establish social distancing and minimize touchpoints. We are very proud that we have been able to provide a safe environment for all of our employees through these safety protocols.

Safety for our ATMI Precast team during this year has always been our first priority. A close second was a concerted and continuous sales effort to get us back to a full backlog by June 1. A large part of this push includes the design and construction of 6 precast concrete parking garages. Two of these parking structures will be delivered by the end of this year, and 4 more will be completed in 2021.

Despite the impact COVID-19 had on our business this year, ATMI Precast expects to sell revenue levels that match 2019. We couldn’t have accomplished this without our excellent employees and our loyal customers.

New Projects & Initiatives

As a result of our amazing ATMI Precast team’s efforts this year, we have been able to participate in a variety of new projects and initiatives. For instance, we’ve continued to follow our general contractor customer base as they construct multiple Amazon projects within Illinois, Indiana and Wisconsin. Check out Project Tarpon and Project W to see what we’ve been up to!

Additionally, this year we implemented a new PCI Certification process for architectural precast. PCI’s plant certification serves as the industry’s benchmark in quality system standards worldwide. ATMI Precast is proud to be PCI-certified.

Our dedication to improvement doesn’t just center around our manufacturing plants. We continue to strive to improve efficiencies in technology across all departments, for example. This year we started ongoing implementation projects in CRM, Tekla and ROI. Of course, we are always looking to further strengthen our relationships with existing customers as well. To do this, we are constantly looking at how we can improve our quality, service and reliability.

Awards & Recognition

It’s always nice to be recognized for our work and fortunately, 2020 was no exception in this category. We are pleased to announce our award for the Facebook Data Center in DeKalb, Illinois. We look forward to working with Mortenson Construction on this exceptional project. ATMI Precast also applied for a PCI Design Award for our work on the Division & Clybourn project in Chicago. We are hoping to hear the results in 2021.

Last, but certainly not least, ATMI Precast is thrilled to have been honored with the MRMH Award. The Assurance Minimizing Risk Maximizing Health Award spotlights companies that have made a significant measurable impact on not only insurance costs, but also employees and their families.

Expansion & World Domination

Maybe not world domination – but certainly expansion! We are excited to have completed expansion of our ATMI Indy facility this year. This plant has nearly doubled capacity to serve the Indiana, Ohio and Kentucky markets and we are proud of their work. We also added 5 engineers to our team this year.

This year has taught us many lessons and one of them is that time is precious, our relationships with people are invaluable and we can overcome just about anything.

If there’s anything we can rely on in the Midwest, it’s that January and February (and sometimes March and April) will bring snow and extreme cold at times. This is usually a roadblock when it comes to construction – but not when it comes to precast concrete. Being able to build during the winter months is a huge benefit to working with precast concrete. Let’s explore how working with precast concrete can help you stay on time and on budget during the winter season.

The Problem: It’s definitely too cold for cast-in-place (CIP) concrete to set.

We talk about extreme cold as being an issue when it comes to setting concrete onsite. However, when the mercury drops below freezing temperatures, CIP concrete isn’t a viable option. In the Midwest region the temperature can get to below freezing as early as November or December. Of course, those temperatures can always stick around until May – it just depends on the year. That means that the “cold weather” season here can technically last as long as 7 months. The solution is building with precast concrete. Since this material is manufactured off-site, in temperature-controlled manufacturing plants, it’s the key to keeping construction going during this time of year.

The Problem: It’s probably too cold for CIP concrete to set.

If you live and work in the Midwest you know that we can wake up with a frost and end up in shorts and t-shirts in the late afternoon. The spring and fall seasons are traditionally unpredictable here, and banking on the accuracy of weather forecasts isn’t what we’d call a guaranteed game plan. If the temperature is hovering around where you need it to be for your concrete products to set, it can be a gamble resulting in inconsistent finishes. But, working with precast concrete products mitigates that risk. Quality control of precast concrete products is ensured by an internal batch plant where the precise aggregate, powder, water and other additives are mixed at a consistent temperature – therefore resulting in a uniform product.

The Problem: It’s too cold to send multiple crews.

When site conditions are tight, it can be downright dangerous to have too many trades onsite during snow and ice events. Minimizing worker exposure to the elements during extreme weather conditions is important to everyone involved – especially contractors. Working with precast concrete eliminates the congestion of having too many workers at the job site, thereby increasing safety.

ATMI Precast has the ability to start the design process and manufacturing prior to beginning on-site activities. Additionally, our year-round unimpeded manufacturing and erection capabilities mean your precast construction will stay on schedule. We offer unmatched economy and speed to complete your project on budget and on time.

This time of year – thanks to Valentine’s Day – we see and hear a lot about LOVE. At ATMI Precast we give, receive, and spread love in a bunch of different ways. One of our biggest loves is working with a solid team on an award-winning project. We’ve done it before – and we’re thrilled to say, we’ve done it again!

ATMI Precast is honored to have won a 2021 PCI Design Award for our work on 1200 Clybourn. The building was selected as “Best Multi-Family Building.”

ATMI Precast Takes Housing Project to Best Multi-Family Building

Our ATMI Precast team worked with general contractor McShane Construction and architect Pappageorge Haymes Partners to make 1200 Clybourn a reality. Once upon a time, Chicago’s Near North Side was once home to Cabrini Green. In 2000, the Chicago Housing Authority began demolishing those towers and replacing them with more modern, durable, and family-friendly homes.

The latest addition to this transformation is Clybourn 1200, a 157,000-ft² mixed-use, mixed-income redevelopment project that leverages precast concrete to provide a resilient, sustainable living and working space for the entire community.

A New Chapter for the North Side

The new design uses precast concrete to create a book-shaped massing for the seven-story building featuring an acute angle to fit the nontraditional infill site. The “spine” of the book, which is located at the narrowest point on the lot, includes full-height glazing with a steel and glass canopy providing a backdrop.

The exterior panels and columns use different planes of relief with features that are either light acid-washed or sandblasted and, with the exception of selected accent areas that are stained dark, the surface is untreated. Window units punctuated with bright contrasting color and alternating orientation from floor to floor play up movement in the elevation and reduce the building mass. The glassy, open base, accented by contrasting colored precast concrete piers and banding accents, provides an active and engaging street presence.

The team at Pappageorge Haymes Partners chose a single precast concrete system and provider for the structure and enclosure to achieve cost and time efficiencies with a durable and attractive solutions. They gained many benefits by combining structural and architectural elements, adds Mike Walsh of ATMI. “We were able to fabricate architectural components that act as the exterior load-bearing frame for the building,” he said.

“It does not look like a precast concrete structure at the first glance,” Walsh adds. “The colors are very vibrant and accented with depth of structure, and you have to look hard to see the subtle differences.”

About the Award

The PCI Design Awards program recognizes design excellence and construction quality using precast concrete. This awards program helps to showcase innovative and advanced technology and ideas. Three jury panels consisting of architects, engineers, and precast concrete producers selected a total of 28 winners and 12 honorable mentions this year. All winning projects and teams will be showcased at the 2021 PCI Convention, May 18-22, in New Orleans.

Our true love is creating functional, sustainable, and beautiful spaces – and it’s nice to be recognized for our efforts!

If you’re considering using precast concrete for your construction project, it’s important to understand how the process works.

1. 1. Concrete is poured onto a wooden or steel table utilizing wire mesh, rebar, and prestressed cable. This first step is done in a controlled inside environment like our ATMI Precast plant in Aurora, Illinois.

1. Once the precast concrete is cured, the pieces are transported to a construction site and erected into place.

But, that’s not quite as easy as it sounds! Most precast manufacturers have to call in an erector to get that last part completed. They may work with several different erectors depending on the location and the scope of the project. At ATMI Precast, we are fortunate to be the only precast manufacturer in the Chicagoland area to have our own controlled erector – Waubonsee Development.

What is a Controlled Erector?

Waubonsee Development is ATMI Precast’s controlled erector, meaning that the company is wholly owned by ATMI. In essence, this means that Waubonsee erects only for ATMI and is not beholden to other project schedules.

What is the Advantage of a Controlled Erector?

There are many advantages the customer benefits from when working with a team like ATMI Precast and Waubonsee Development.

1. 1. Accurate Sales & Estimating: ATMI Precast is able to accurately forecast from the erection side since both manufacturing and erection are under the same company.

1. 1. Consistent Crews: Waubonsee operates up to 4 crews at a time. This means that workers are able to stay on Waubonsee crews for longer periods of times and receive daily training on safety and erection protocols.

1. 1. Access to Cranes: Waubonsee Development owns its own conventional cranes for the warehouse market, which can streamline the construction process.

1. 1. Competitive Prices: Waubonsee is in a position to be very competitive when it comes to pricing since it only services ATMI Precast.

1. Advanced Scheduling: Erection scheduling is planned well in advance and matches our production schedule.

Sometimes coordinating outside subcontractors and their schedules can be a hassle. Working with a team like ATMI Precast and Waubonsee Development takes that potential out of the mix.

About Waubonsee Development

Since opening its doors in 1980, Waubonsee Development has grown to employ over 70 employees. Every year Waubonsee erects more than 75 precast building systems and that number continues to grow. Skilled in a variety of projects, from construction of precast parking garages and warehouses to retail, multi-story residential buildings, and field finishing and caulking, Waubonsee Development has the talent to take on any task.